Reduced material container

ABSTRACT

A reduced material container having a base with sidewalls extending from the base to define a compartment for storing goods. The sidewalls define a plurality of apertures that are covered by a sleeve. A lid removeably seats with the sidewalls. The apertures allow production of a container with a reduced amount of material and energy and has a reduced environmental impact.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to U.S. Provisional Patent Application No. 60/913,939 filed Apr. 25, 2007 from which priority is claimed, and is hereby incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention relates generally to containers, and more specifically to a reduced material container produced with a reduced amount of material relative to conventional containers to have a reduced environmental impact.

Various types of containers (also commonly referred to as packages) have been used in for shipping and storage for years, in particular for retail consumer products. Typically, conventional containers include solid walls defining a storage comportment, which are produced using a variety of manufacturing processes including, but not limited to injection-molding, blow-molding, and thermoforming. Containers are produced with specified attributes, such as retaining moisture, preventing moisture, or prolonging shelf life of the products contained therein, to accommodate the requirements of different applications. In particular, the retail consumer industry uses containers in a host of applications for storing and transporting an almost endless number of products to the consumer, including, but not limited to baby wipes, cleaning wipes, cleaning pads, detergent products, pet products, personal care products, food products, cigarettes, and the like.

However, conventional containers have numerous disadvantages due to the significant amounts of materials and energy required to produce containers that meet the specifications and performance required by current quality standards. In addition to the various molding processes noted above, conventional containers typically require many additional processes to produce a finished container. These additional processes can include, but are not limited to, filling processes, sealing processes, and adding tamper resistant elements, ornamental elements, and environmental elements for controlling conditions within the container, such as moisture content or gas content. Thus, the large number of materials and processes required along with the inefficiency of the individual processes make production of containers highly inefficient, wasteful, and uneconomical, which all have a negative environmental impact.

Therefore, there has been a long felt need for a cost-effective container that uses a reduced amount of material and is produced with fewer more efficient manufacturing processes to have a reduced environmental impact.

DESCRIPTION OF THE DRAWINGS

In the accompanying drawings which form part of the specification:

FIG. 1 is an orthographic view of a reduced material container in accordance with and embodying the present invention;

FIG. 2 is an orthographic view of the reduced material container with a portion cut-away;

FIG. 3 is a top view of a body of the reduced material container;

FIG. 4 is a orthographic view of the body of the reduced material container;

FIG. 5 is a side view of the body of the reduced material container;

FIG. 6 is an end view of the body of the reduced material container;

FIG. 7 is an orthographic view of a first alternate embodiment of a reduced material container with a portion cut-away;

FIG. 8 is a orthographic view of a body of the first alternate embodiment of the reduced container;

FIG. 9 is an orthographic view of a body of a second alternate embodiment of the reduced container;

FIG. 10 is a side view of the body of the second alternate embodiment of the reduced container; and

FIG. 11 is an orthographic view of a body of a third alternate embodiment of a reduced container.

Corresponding reference numerals indicate corresponding parts throughout the several figures of the drawings.

DETAILED DESCRIPTION

The following detailed description illustrates the invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the invention, describes several embodiments, adaptations, variations, alternatives, and uses of the invention, including what is presently believed to be the best mode of carrying out the invention. Additionally, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

As shown in FIGS. 1-6, an embodiment of the present invention, generally referred to as a reduced material container 10, includes a hollow body 12 surrounded by a sleeve 14 that defines a compartment 16 for receiving and storing solid or liquid goods. A removeable lid 18 seats against a rim 20 about an opening 22 to the compartment 16.

The body 12 is generally rectangular having four sidewalls 24 extending vertically from a base 26 to define the compartment 16 and opening 22 thereto. Each sidewall 24 is a generally grid-like framework having horizontal and vertical crosspieces 28 that define a plurality of apertures 30. The grid-like framework provides the container 10 with the structural integrity to withstand the stresses of filling, storage, distribution, and merchandising. Although the sidewalls 24 of FIGS. 1-6 are a grid-like framework, the sidewalls 24 can encompass any arrangement of framework that reduces the amount of material in the body 12 while maintaining the structural integrity of the body 12, including but not limited to lattice-like, diamond-like, circular, honeycomb, reticular, helical, and other arrangements. The sidewalls 24 are slightly tapered so that the perimeter of the rim 20 is larger than the perimeter of the base 26. This allows stacking of the container 10 within another container.

Protrusions 34 on the sidewalls 24 enhance the stability of the sidewalls 24 and aid engagement of the sleeve 14 with the sidewalls 24. In the embodiment of FIGS. 1-6, the protrusions 34 are preferably raised ridges positioned along both the horizontal and vertical crosspieces 28, including a parametric upper ridge 36 and a parametric lower ridge 38. For further stability, the protrusions 34 can be positioned along both an inner surface 40 and an outer surface 42 of the sidewalls 24. Protrusions 34 can be positioned strategically at predetermined locations along the sidewalls 24 to enhance stability at desired areas. For example, the placement of the parametric upper ridge 36 along the rim 20 of the container 10 enhances the rim's ability to withstand repeated opening and closing of the lid 18. The placement, shape, and size of protrusions 34 along the sidewalls 24 can be altered to accommodate any number of different sizes, shapes, and functions of containers.

In production, the body 12 is preferably produced as a unitary piece using a suitable process, such as injection molding. The body 12 is preferably made with virgin or nor-virgin polymers, paperboard or metals, but other materials can also be used including, but not limited to recycled polymeric material such as PE, PP and PET. The apertures 30 reduce the amount of material required to produce the container 10. To further reduce the amount of material needed, gas or material additives, such as calcium carbonate or talc, can be injected into the material.

The lid 18 is generally rectangular and corresponds to the size and shape of the rim 20 so that the lid 18 removeably seats against the rim 20 to seal product within the container 10. The lid 18 is also preferably produced as a unitary piece using a suitable process, such as injection molding. While the lid 18 is preferably made with virgin or nor-virgin polymers, paperboard or metals, but other materials can also be used including, but not limited to recycled polymeric material such as PE, PP and PET. The amount of material needed to produce the lid 18 can also be reduced by injection of gas or material additives, such as calcium carbonate or talc, into the material. By using less material in the body 12 and lid 18, the manufacturing time of the container 10 is reduced due to faster molding and curing cycles. The reduced amount of material and more efficient processes produce a container 10 having a reduced environmental impact.

In alternate embodiments, the lid 18 can moveably attach to the body 12 with hinges, snaps, fasteners, and the like. In addition, the lid 18 can include a moveably attached secondary lid (not shown) that can be independently opened without opening lid 18 to allow extraction of product from the container. Although the lid 18 of FIGS. 1-6 is separate from the container 10, the lid 18 can also be formed integral with the container 10, such as with a hinge. The secondary lid may also be located such that the lid 18 itself or a tab extending from the lid 18 extends to one side of the lid 18 to allow for sleeving to lock the secondary lid and lid 18 in place so that neither lid can be opened without removing the sleeve section overlapping the two lids.

Alternatively, the body 12 and lid 18 can be produced as multiple pieces. For example, the base 26 can be formed separately and attached to the base 26. This may be desirable when the base 26 includes additional features for holding the body 12 of the container 10 erect, promoting better stackability of the container 10, or providing an additional means of dispensing or filling the container 10 with product.

In alternate embodiments, hinges can be molded into the body 12 for moveable attachment to the lid 18. Similarly, the lid 18 can include integral hinges to moveably attach to the body 12. The lid 18 can be replaced by various other forms of sealing the opening of the container including, but not limited to foils, films, and laminates of varying types.

The sleeve 14 is a film or substrate, preferably a bio-degradable polymer material, that seals against the sidewalls 24, base 26, and lid 18 (FIGS. 1-2). The sleeve can comprise any suitable film or substrate, such as shrink-wrap or pre-printed material. Although in other embodiments, the sleeve 14 can also seal to a limited portion of the container 10, such as only to the sidewalls 24. However, the sleeve 14 should seal to at least the portion of the body 12 defining the apertures 30 to insure all the apertures 30 are covered by the sleeve 14. Otherwise, product within the compartment 16 may become exposed through the apertures 30. The protrusions 34 frictionally engage the sleeve 14 to further secure and limit movement of the sleeve 14. In assembly, as the shrink-wrap sleeve shrinks or contracts about the sidewalls 24, the upper ridge 36 and lower ridge 38 engage and create tension across the sleeve 14, thereby sealing the sleeve 14 to the body 12. If desired, an adhesive or heat-seal bond can be applied between the sleeve 14 and the body 12 to enhance the engagement and seal between the two elements.

The sleeve 12 includes a removable perforated section 44 about the lid 18 for tamper resistance purposes, which can be removed by the consumer after purchase. However, the perforated section 44 can also be placed at other portions of the container 10. In operation, the consumer removes the perforated section 44 from the sleeve 14, revealing the lid 18. The consumer can now remove the lid 18 for access to the product within the compartment 16 of the container 10. Thereafter, the consumer reseats the lid 18 onto the rim 20, thereby resealing the product within the container 10.

Indicia 46 can be placed on the sleeve 14, such as advertising, logos, instructions, warnings, and the like. For instance, indicia 46 can be placed on the perforated section 44, such as a coupon for the consumer that can be redeemed after removal. Any suitable method can be used to place the indicia 46 onto the sleeve 14, such as printing, dying, engraving, etching, and the like. Indicia 46 can also be placed on the lid 18 or the body 12.

Those skilled in the art will recognize that the sleeve 14 can comprise any suitable material, such as polymeric extruded, co extruded, cast, laminated sheet and film material such as polyolefin's, polyesters, nylons and coated cellophanes. The sleeve 14 can be monolayer or multilayered, or one material or multi-material. Also, sleeve materials can be selected with specific properties to impart different functions to the container 10. For example, a material with barrier properties to prevent entrance of contaminants, dirt, gases or high moisture can be selected for or applied to the sleeve # to retain moisture within the container 10, such as “eval” (or “EVOH”), olefinic polymers, high density polyethylene (HDPE), polypropylene (PP), oriented polypropylene (OPP), polystyrene (PS), high-impact polystyrene (HIPS), polyethylene terephthalate (PET and PETG), polyvinylidene chloride (PVC), various copolymers, and high nitrile barrier resins.

The present invention can also be embodied in the form of FIGS. 7, 8, 9-10, and 11, which are generally similar to FIGS. 1-6. For ease of understanding, components common between the embodiments and second embodiments are identified with similar reference numbers, except the reference numbers in the subsequent embodiments include a numerical prefix, such as “100”. For example, the body of the FIG. 1-6 embodiment is identified as 12, while a FIG. 7 embodiment with a similar body is identified as 112. Naturally, any new components are identified with unique reference numbers. Similar elements are produced using similar materials and process as those described for the embodiment of 1-6 and will not be reiterated here.

FIG. 7 illustrates a reduced material container 110 including a hollow body 112 surrounded by a sleeve 114 that defines a compartment 116 for receiving and storing solid or liquid goods. A removeable lid 118 seats against a rim 120 about an opening 122 to the compartment 116.

The body 112 is generally cylindrical having a cylindrical sidewall 124 extending vertically from a base 126 to define the compartment 116 and opening 122 thereto. The sidewall 124 is a generally grid-like framework having horizontal and vertical crosspieces 128 that define a plurality of apertures 130. Although the sidewall 124 of FIG. 7 is a grid-like framework, the sidewall 124 can encompass any arrangement of framework that reduces the amount of material in the body while maintaining the structural integrity of the body 112, including but not limited to lattice-like, diamond-like, circular, honeycomb, reticular, and other arrangements.

Protrusions 134 on the sidewall 124 enhance the stability of the sidewall 124 and aid engagement of the sleeve 114 with the sidewall 124. In the embodiment of FIG. 7, the protrusions 134 are preferably raised ridges positioned along crosspieces 128, including a parametric upper ridge 136 and a parametric lower ridge 138. For further stability, the protrusions 134 can be positioned along both the inner surface 140 and outer surface 142 of the sidewall 124. Protrusions 134 can be positioned strategically at predetermined locations along the sidewall 124 to enhance stability at desired areas. For example, the placement of the parametric upper ridge 136 along the rim 120 of the container 110 enhances the rim's ability to withstand repeated opening and closing of the lid 118. The placement, shape, and size of protrusions 134 along the sidewall 124 can be altered to accommodate any number of different sizes, shapes, and functions of containers.

In production, the body 112, the lid 118, and the sleeve 114 are produced using similar materials and process as those described for the embodiment of 1-6. Therefore, they will not be reiterated here.

The sleeve 114 includes a removable perforated section 144 about the lid 118 for tamper resistance purposes, which can be removed by the consumer after purchase. However, the perforated section 144 can also be placed at other portions of the container 110. In operation, the consumer removes the perforated section 144 from the sleeve 114, revealing the lid 118. The consumer can now remove the lid 118 for access to the product within the compartment 116 of the container 110. Thereafter, the consumer reseats the lid 118 onto the rim 120, thereby resealing the product within the container 110.

Indicia 146 can be placed on the sleeve 114, such as advertising, logos, instructions, warnings, and the like. For instance, indicia 146 can be placed on the perforated section 144, such as a coupon for the consumer that can be redeemed after removal. Any suitable method can be used to place the indicia 146 onto the sleeve 114, such as printing, dying, engraving, etching, and the like. Indicia 146 can also be placed on the lid 118 or the body 112.

The present invention can also be embodied in the form of FIG. 8, which is generally similar to FIG. 7 except for changes in the framework of the sidewall 224. Generally, the crosspieces 228 have tapered faces 250 to further reduce the amount of material while maintaining structural integrity of the container 210.

The present invention can also be embodied in the form of FIGS. 9-10, which is generally similar to FIG. 7 except for changes in the framework of the sidewall 324. The sidewall 324 is a generally lattice framework having horizontal and vertical crosspieces 328 that define a plurality of triangular-shaped apertures 330. In addition, the sidewall 324 is slightly tapered so that the perimeter of the rim 200 is larger than the perimeter of the base 326. This allows stacking of the container 310 within another container.

The present invention can also be embodied in the form of FIG. 11. The body 412 is generally rectangular having four sidewalls 424 extending vertically from a base 426 to define the compartment 416 and opening 422 thereto. Each sidewall 424 is a framework of horizontal and vertical crosspieces 428 that define a plurality of apertures 430. The framework provides the container 410 with the structural integrity to withstand the stresses of filling, storage, distribution, and merchandising.

Protrusions 434 on the sidewalls 424 enhance the stability of the sidewalls 424 and aid engagement of the sleeve 414 with the sidewalls 424. In the embodiment of FIG. 11, the protrusions 434 are preferably raised ridges positioned along both the horizontal and vertical crosspieces 428, including a parametric upper ridge 436 and a parametric lower ridge 438. For further stability, the protrusions 434 can be positioned along both the inner surface 440 and outer surface 442 of the sidewalls 414. Protrusions 434 can be positioned strategically at predetermined locations along the sidewalls 424 to enhance stability at desired areas. For example, the placement of the parametric upper ridge 436 along the rim 438 of the container 410 enhances the rim's ability to withstand repeated opening and closing of the lid 418. The placement, shape, and size of protrusions 434 along the sidewalls 424 can be altered to accommodate any number of different sizes, shapes, and functions of containers.

With respect to the above description then, the optimum dimensional relationships for the parts of the invention can include variations in size, materials, shape, form, function and manner of operation, assembly and use. Moreover, all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

Changes can be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 

1. A reduced material container, comprising: a base; a sidewall extending from the base and defining a compartment for receiving goods, wherein the sidewall defines a plurality of apertures; a lid removeably seated with the sidewall; and a sleeve attached to the body and positioned over the plurality of apertures.
 2. The reduced material container of claim 1, further comprising a protrusion positioned on the sidewall for engagement with the sleeve.
 3. The reduced material container of claim 1, further comprising: an upper ridge positioned on the sidewall; a lower ridge positioned on the sidewall; and wherein the sleeve seats against the upper ridge and the lower ridge.
 4. The reduced material container of claim 1, further comprising, an adhesive between the sleeve and the sidewall.
 5. The reduced material container of claim 1, wherein the sidewall is a grid-like framework.
 6. The reduced material container of claim 1, wherein the sidewall is tapered to allow stacking of multiple containers.
 7. The reduced material container of claim 1, wherein the sleeve is a heat shrink material.
 8. The reduced material container of claim 1, wherein the base and sidewalls are a recycled material.
 9. The reduced material container of claim 1, the sleeve further comprising, a removeable perforated section about the lid.
 10. The reduced material container of claim 1, further comprising, indicia on the sleeve.
 11. A system for storing goods reduced material containers, comprising: a body defining a compartment, an opening, and a plurality of apertures; goods residing within the compartment; a lid removeably sealed to the body, wherein the lid can be removed to access the goods; and a sleeve attached to the body and positioned over the plurality of apertures.
 12. The reduced material container of claim 11, further comprising a protrusion positioned on the body for engagement with the sleeve.
 13. The reduced material container of claim 11, further comprising: an upper ridge positioned on the body; a lower ridge positioned on the body; and wherein the sleeve seats against the upper ridge and the lower ridge.
 14. The reduced material container of claim 11, further comprising, an adhesive between the sleeve and the body.
 15. The reduced material container of claim 11, wherein the body is a grid-like framework.
 16. The reduced material container of claim 11, wherein the body is tapered to allow stacking of multiple containers.
 17. The reduced material container of claim 11, wherein the sleeve is a heat shrink material.
 18. The reduced material container of claim 11, wherein the body is a recycled material.
 19. The reduced material container of claim 11, the sleeve further comprising: a removeable perforated section about the lid.
 20. A reduced material container, comprising: a body defining a compartment for receiving goods and a plurality of apertures; a sleeve sealed to the body and positioned over the plurality of apertures an upper ridge positioned on the body and engaged with the sleeve; a lower ridge positioned on the body and engaged with the sleeve; and a lid removeably seated with the body. 